Utilizing Wet Fracturing Sand For Hydraulic Fracturing Operations

ABSTRACT

A system and a method that utilizes wet proppants when creating fracturing fluid by receiving wet fracturing sand at a surge tank, vibrating the wet fracturing sand located within the surge tank, liquefying the wet fracturing sand within the surge tank based on the vibration, and metering the liquefied wet fracturing sand from the surge tank to a blending tub.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.15/452,415, filed Mar. 7, 2017 by Jeffrey G. Morris et al. and entitled“Utilizing Wet Fracturing Sand for Hydraulic Fracturing Operations,”which claims the benefit of U.S. Provisional Patent Application No.62/305,449, filed Mar. 8, 2016 by Jeffrey G. Morris et al. and entitled“Utilizing Wet Fracturing Sand for Hydraulic Fracturing Operations,” allof which is hereby incorporated by reference as if reproduced in itsentirety.

BACKGROUND

Hydraulic fracturing has been commonly used by the oil and gas industryto stimulate production of hydrocarbon producing wells, such as oiland/or gas wells. Hydraulic fracturing, sometimes called “fracing” or“fracking” is a process of injecting fracturing fluid, which istypically a mixture of water, proppants (e.g., sand, fracturing sand,ceramics and resin coated materials), and chemicals, into the wellboreto fracture the subsurface geological formations and release hydrocarbonreserves. The fracturing fluid is pumped into a wellbore at a sufficientpressure to cause fissures within the underground geological formations.Once inside the wellbore, the pressurized fracturing fluid flows intothe subsurface geological formation to fracture the undergroundformation. The fracturing fluid may include water, various chemicaladditives, and proppants that promote the extraction of the hydrocarbonreserves, such as oil and/or gas. Proppants, such as fracturing sand,prevent fissures and fractures in the underground formation fromclosing, and for the formation to remain open so that hydrocarbonreserves are able to flow to the surface.

Hydraulic fracturing generally uses large amounts of sand (e.g., aboutfive to fifty million pounds per well) to aid in the fracturing ofwells. Prior to transport to the well site, the sand undergoesprocessing to: (1) remove impurities, (2) to dry the fracturing sand inorder for it to meet American Petroleum Institute (API) recommendedpractices (i.e., RP 19C, 56, 58, and 60) and (3) to make it suitable formetering into the mixing process using conventionally employed hydraulicfracturing process equipment (e.g., fracturing blender) to produce aslurry or fracturing fluid. Mining and/or processing operators initiallymine for fracturing sand within sand deposits that contain quartz grainswith desired properties, such as relatively high crush strength androundness. To satisfy fracturing criteria, the operators process themined sand by washing it to remove impurities and subsequently dryingthe sand to remove moisture. Mining operators may then further filterout sand particles that fail to satisfy specific size criteria forfracturing operations. Once processing is complete, operators load anddeliver the fracturing sand to well sites that may be hundreds of milesfrom the point of origin using specialized rail cars, trailers (e.g.,hopper trailers and pneumatic vessels), and trucks that protectfracturing sand from environmental exposure. Operators use silos, domes,and other large and expensive storage vessels to store the dry sand atvarious points along the supply chain. Maintaining dry fracturing sandprior to mixing to form fracturing fluid increases an operator's abilityto reliably control and meter the flow of fracturing sand. In contrast,wet fracturing sand normally clumps together causing its flow to be lessconsistent and more difficult to meter for fracturing purposes.Unfortunately, drying, transporting, and storing vast quantities of dryfracturing sand increases financial, operating, and logistical costsassociated with fracturing operations.

SUMMARY

The following presents a simplified summary of the disclosed subjectmatter in order to provide a basic understanding of some aspects of thesubject matter disclosed herein. This summary is not an exhaustiveoverview of the technology disclosed herein. It is not intended toidentify key or critical elements of the invention or to delineate thescope of the invention. Its sole purpose is to present some concepts ina simplified form as a prelude to the more detailed description that isdiscussed later.

In one embodiment, a system for utilizing wet proppants when creatingfracturing fluid, comprising: a surge tank, a vibration componentdisposed with the surge tank and configured to liquefy wet proppantsreceived by the surge tank, and a metering system coupled to the surgetank, wherein the metering system is configured to control an amount ofthe liquefied wet proppants that is outputted to a blending tub.

In another embodiment, a method for utilizing wet proppants whencreating fracturing fluid, the method comprising: receiving wetfracturing sand at a surge tank, vibrating the wet fracturing sandlocated within the surge tank, liquefying the wet fracturing sand withinthe surge tank based on the vibration, and metering the liquefied wetfracturing sand from the surge tank to a blending tub.

In yet another embodiment, a surge tank for utilizing wet proppants whencreating fracturing fluid comprising: a vibration component affixed toan outer surface of the surge tank to cause vibration of wet proppantsthat enter the surge tank and an auger coupled to the surge tank,wherein the auger is configured to meter liquefied wet proppants outputinto a blending tub.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of this disclosure, reference is nowmade to the following brief description, taken in connection with theaccompanying drawings and detailed description, wherein like referencenumerals represent like parts.

FIG. 1 is a schematic diagram of an embodiment of a well site thatincludes a wet fracturing sand agitation system capable of moving andliquefying wet fracturing sand utilized for producing fracturing fluid.

FIG. 2 illustrates a top-down view of an embodiment of a surge tank thatcomprises a plurality of vibrating components.

FIG. 3A illustrates a side view of an embodiment of a surge tank thatcomprises a plurality of vibrating components and a vibration isolationsystem.

FIG. 3B illustrates a side view of an embodiment of a surge tank thatcomprises a plurality of vibrating components and a vibration isolationsystem.

FIG. 4A illustrates a top-down view of an embodiment of a surge tankthat comprises an internal vibrating component.

FIG. 4B illustrates a side view of an embodiment of a surge tank thatincludes an internal vibrating component and vibration isolation system.

FIG. 5A illustrates a top-down view of an embodiment of a mobileconveyor system adapted to allow fracture sand transports to drive up toand directly load fracturing sand onto the mobile conveyor system.

FIG. 5B illustrates a side view of an embodiment of a mobile conveyorsystem adapted to allow fracture sand transports to drive up to anddirectly load fracturing sand onto the mobile conveyor system.

FIG. 6 is a flow chart of an embodiment of a method to provide andutilize wet fracturing sand for hydraulic fracturing.

FIG. 7 is a schematic diagram of an embodiment of a wet fracturing sandagitation system that includes a bulk storage tank positioned above thesurge tank.

While certain embodiments will be described in connection with theillustrative embodiments shown herein, the invention is not limited tothose embodiments. On the contrary, all alternatives, modifications, andequivalents are included within the spirit and scope of the invention asdefined by the claims. In the drawing figures, which are not to scale,the same reference numerals are used throughout the description and inthe drawing figures for components and elements having the samestructure, and primed reference numerals are used for components andelements having a similar function and construction to those componentsand elements having the same unprimed reference numerals.

DETAILED DESCRIPTION

In the following description, for purposes of explanation, numerousspecific details are set forth in order to provide a thoroughunderstanding of the invention. It will be apparent, however, to oneskilled in the art that the invention may be practiced without thesespecific details. In other instances, structure and devices are shown inblock diagram form in order to avoid obscuring the invention. Referencesto numbers without subscripts or suffixes are understood to referenceall instance of subscripts and suffixes corresponding to the referencednumber. Moreover, the language used in this disclosure has beenprincipally selected for readability and instructional purposes, and maynot have been selected to delineate or circumscribe the inventivesubject matter, resort to the claims being necessary to determine suchinventive subject matter. Reference in the specification to “oneembodiment” or to “an embodiment” means that a particular feature,structure, or characteristic described in connection with theembodiments is included in at least one embodiment of the invention, andmultiple references to “one embodiment” or “an embodiment” should not beunderstood as necessarily all referring to the same embodiment.

The terms “a,” “an,” and “the” are not intended to refer to a singularentity unless explicitly so defined, but include the general class ofwhich a specific example may be used for illustration. The use of theterms “a” or “an” may therefore mean any number that is at least one,including “one,” “one or more,” “at least one,” and “one or more thanone.” The term “or” means any of the alternatives and any combination ofthe alternatives, including all of the alternatives, unless thealternatives are explicitly indicated as mutually exclusive. The phrase“at least one of” when combined with a list of items, means a singleitem from the list or any combination of items in the list. The phrasedoes not require all of the listed items unless explicitly so defined.

The term “fracturing sand,” as used within this disclosure, serves as anon-limiting example of a proppant used as a component of fracturingfluid. “Fracturing sand” is also used herein to collectively refer toboth wet and dry fracturing sand. Embodiments in this disclosure are notlimited to fracturing sand and any other type of proppant, such asman-made ceramics, aluminum beads and sintered bauxite, can be used withthe various embodiments presented in the disclosure. Unless otherwisespecified within the disclosure, the term “fracturing sand” can beinterchanged with and considered synonymous throughout this disclosurewith the term “proppants.”

As used herein, the term “wet fracturing sand” refers to a quantity offracturing sand that contains a moisture content of about one percent ormore, which is typically determined based on weight. The term “dryfracturing sand” refers to quantities of fracturing sand that contain amoisture content of less than about one percent.

As used herein, the term “liquefying wet fracturing sand” refers toenhancing and transforming the flow properties of wet fracturing sand tobe substantially similar to dry fracturing sand in order to accuratelycontrol the amount of metered fracturing sand. For example, wetfracturing sand can liquefy and have flow properties similar to dryfracturing sand with the assistance of mechanical forces and/or soundwaves.

As used herein, the term “transport” refers to any transportationassembly, including, but not limited to, a trailer, truck, skid, railcar, and/or barge used to transport relatively heavy structures and/orother types of articles, such as fracturing equipment and fracturingsand.

As used herein, the term “trailer” refers to a transportation assemblyused to transport relatively heavy structures and/or other types ofarticles, such as fracturing equipment and fracturing sand that can beattached and/or detached from a transportation vehicle used to pull ormove the trailer. In one embodiment, the trailer may include mounts andmanifold systems to connect the trailer to other fracturing equipmentwithin a fracturing system or fleet.

Unless otherwise specified within the disclosure, the term “surge tank”can be interchanged with and considered synonymous throughout thisdisclosure to the term “hopper.”

Various example embodiments are disclosed herein that deliver and/orutilize wet fracturing sand for fracturing operations at one or morewell sites. Rather than drying and/or transporting dry fracturing sandto a well site for fracturing operations, fracturing sand may betransported to a well site for fracturing operators without usingspecialized transport (e.g., dry bulk tank trailers) or transportationcontainers designed to prevent exposure to rain, moisture, and/or otherenvironmental factors that impact the dryness level of the fracturingsand. Once the transports deliver the fracturing sand to the well site,well-site operators are able to store the fracturing sand without usingspecialized storage facilities and/or containers (e.g., storage silos)that maintain the relatively low moisture levels required in dryfracturing sand. To produce the fracturing fluid at the well site, thefracturing sand may be moved from a storage site using one or moremechanical means (e.g. front end loaders) that provide the fracturingsand to a conveyor system. The conveyor system subsequently delivers thefracturing sand to a surge tank (e.g., a blender hopper). To processfracturing sand with varying moisture content levels, the surge tankcomprises a plurality of vibration components that are adapted to breakbonds (e.g., cohesive bonds) created from the surface tension of waterthat affix particles in fracturing sand together. In one embodiment, thevibration components provide mechanical vibration forces that directlyagitate the wet/dry fracturing sand. Additionally, or alternatively, thevibration components provide mechanical vibration forces that agitatethe surge tank assembly containing the fracturing sand. In anotherembodiment, the vibration component generates sound waves that traversethe surge tank to separate fracturing sand particles. Once separated, ametering system (e.g., one or more augers) may control and meter thefracturing sand into a blending module (e.g., a blender tub) to producefracturing fluid.

FIG. 1 is a schematic diagram of an embodiment of a well site 100 thatincludes a wet fracturing sand agitation system capable of moving andliquefying wet fracturing sand for mixing with fracturing fluid. Thewell site 100 comprises one or more well heads (not illustrated inFIG. 1) that the wet fracturing sand agitation system is setup as acomponent, portion, and/or subsystem of a fracturing system. Initially,to produce fracturing fluid for fracturing the wells, vendors transportproppants, such as fracturing sand, to the well site 100 using a varietyof transportation methods, such as trucks, trailers, rail cars, and/orshipping vessels. In one embodiment, the fracturing sand is delivered tothe well site as wet fracturing sand without using specializedcontainers and/or equipment to maintain a designated moisture level fora dry bulk load. By doing so, operators may be able to reduce product,transportation, and/or storage costs associated with delivering dryfracturing sand to a well site for fracturing operations. Although thewet fracturing sand agitation system used in FIG. 1 is capable of mixingwet fracturing sand with fracturing fluid, the wet fracturing sandagitation system is not limited to using wet fracturing sand and couldbe compatible with processing dry fracturing sand.

The well site 100 may include one or more fracturing sand storage sites102. Transports 104 (e.g., a conventional dump truck) may movefracturing sand from offsite and/or other onsite locations to thefracturing sand storage sites 102. In one embodiment, to reduce wellsite costs, the fracturing sand storage sites 102 do not includeenclosed boxes, containers, storage silos, and/or other storage systems(e.g., fracturing sand storage trailers) designed to prevent exposingdry bulk loads (e.g., dry fracturing sand) to moisture. Instead, thefracturing sand storage sites 102 include uncovered containers and/oruncovered piles of fracturing sand. Additionally, or alternatively,rather than vacuuming or using other means to prevent the release ofsilica dust caused from storing and handling the fracturing sand,operators may use a liquid spray system to maintain a pre-determinedmoisture level range for wet fracturing sand stored at the fracturingsand storage sites 102. Introducing moisture into fracturing sand tobind the sand particles together could reduce/prevent the release ofsilica dust into the air while reducing operating costs.

Operators may move fracturing sand from the fracturing sand storagesites 102 onto a conveyor system 106 using one or more front end loaders116, other transports 104, and/or other mechanical means known bypersons of ordinary skill in the art. The conveyor system 106 is adaptedto receive the fracturing sand and move the fracturing sand to the surgetank 122. The conveyor systems 106 may include a variety of transloadingequipment, such as conveyor belts, conveyor loaders, augers, bucketsystems, screw conveyors and/or pneumatic conveyors powered bydiesel/gas engines, other mechanical means, and/or electrical meansknown by persons of ordinary skill in the art. The conveyor system 106may be adapted to deliver fracturing sand at a predetermined rate to thesurge tank 122. The amount of fracturing sand the conveyor system 106delivers to the surge tank may fall within a tolerance range since thesurge tank 122 is capable of handling surges or degrees of variance onthe amount of input fracturing sand. For example, conveyor system 106could be adapted to deliver up to about 20,000 pounds (lbs) of sand perminute. The amount of fracturing sand delivered by the conveyor system106 could depend on the amount of fracturing sand the surge tank 122 isset to process and/or meter into a blender tub of a fracturing blendingmodule. For example, the conveyor system 106 may be configured tosynchronize with surge tank 122 to deliver enough fracturing sand tocompensate for rate change increases or decreases associated withpumping fracturing fluid into a well. In this instance, the conveyorsystem 106 could compensate for rate change increase by deliveringfracturing sand at a rate greater than 20,000 lbs of sand per minute.

In one embodiment, the conveyor system 106 includes a conveyor storagecontainer 108 that temporarily stores the fracturing sand and assists intransferring fracturing sand to a conveyor assembly 110. To improvemobility of the conveyor storage container 108, the fracturing sandstorage container 108 may comprise a plurality of container segments 112(including pads and sidewalls) that are connected together. FIG. 1illustrates an embodiment of a conveyor storage container 108 thatcomprises four different container segments 108, where three ends of theconveyor storage container 108 are propped up to build side walls.Entrance 114 of the conveyor storage container 108 allows for a frontend loader 116 or other transport 104 to enter, move and/or place sandwithin the conveyor storage container 108. The conveyor storagecontainer 108 may include a conveyor transport component 118 that movesfracturing sand stored in the conveyor storage container 108 to theconveyor assembly 110. The conveyor storage container 108 and conveyorassembly 110 may be connected via a connection well 120. The conveyorassembly 110 may then transport the fracturing sand to the surge tank122. Other embodiments of the conveyor system 106 may use differentconveyor storage containers 108 and/or conveyor assembly 110 to move andtransfer fracturing sand, for example, the mobile conveyor system 500 asdescribed in FIGS. 5A and 5B.

When the fracturing sand reaches the surge tank 122, the surge tank 122reduces clumping of the wet fracturing sand by breaking bonds (e.g.,cohesion bonds) between water and the fracturing sand particles. Thesurge tank 122 can be configured to break the bonds using one or morevibrator components to liquefy the wet fracturing sand and reduce sandclumping. The surge tank 122 may receive from the conveyor system 106wet fracturing sand that is relatively difficult to meter and controlwhen directly supplying the fracturing sand to a hydraulic fracturingblender tub. By using vibrator components to liquefy the sand, the surgetank 122 is able to enhance the flow properties of wet fracturing sandin order to accurately control the amount of metered fracturing sand.

In one embodiment, the vibrator components directly vibrate and screenthe wet fracturing sand while minimizing vibration forces experienced bythe surge tank 122. Additionally, or alternatively, one or more of thevibrator components can be adapted to generate a mechanical shakingforce on the surge tank 122 to break the cohesion bonds of the wetfracturing sand. In another embodiment, the vibrator components areadapted to generate sound waves that cause vibrations within the wetfracturing sand to break the cohesion bonds. Other types of vibrationcomponents known to the art may be used as desired, and combinations ofdifferent types of vibration components may be used. A metering system,such as an auger, a gate, a venturi, and/or any other metered conveyorknown by persons of ordinary skill in the art, may then meter theliquefied fracturing sand into a blending module (e.g., a blender tub).A blending module may then mix the controlled amount of wet fracturingsand with other fluids to generate fracturing fluid.

The vibrator components may be powered by a variety of power sourcesthat include, but are not limited to, air pressure, hydraulics, and/orelectricity. Pneumatic and hydraulic vibrators may be controlled byadjusting the air and hydraulic pressures, respectively. In oneembodiment, to power the pneumatic and/or hydraulic vibrators, one ormore diesel/gas engines and/or other mechanical means may be used as apower source. In other embodiments where the vibrator components arepowered by electricity, operators may use electric motors and electricdrives (e.g., variable frequency drives) to control the vibrationintensity and/or duration of the vibration either directly orindirectly. For example, one or more vibrator components may be poweredusing hydraulics systems that are powered by one or more electricmotors. Specifically, the electric motors are used to power hydraulicpumps to provide the hydraulic pressure used to operate the vibratorcomponents. By controlling the electric motors, an operator is able toindirectly control the one or more vibrator components via the hydraulicpressure. In another example, operators are able to control the one ormore vibrator components directly by connecting one or more electricmotors to one or more vibrator components. Adjusting the electricmotors' attributes, such as frequency, voltage, and/or amperage couldvary operation of the vibrator components.

The surge tank 122 depicted in FIG. 1 is applicable to any blendingoperation for mixing and producing fracturing fluid. In particular, thesurge tank 122 may be mounted on conventional blender modules powered bydiesel/gas engines, pneumatic, electric blender modules, and/or otherwell-known hydraulic fracturing blending equipment and/or transports. Asa non-limiting example, the surge tank 122 may be mounted on a dualconfiguration electric blender that comprises electric motors for therotating machinery located on a single transport, which is described inmore detail in U.S. Pat. No. 9,366,114, filed Apr. 6, 2012 by Todd Coliet al. and entitled “Mobile, Modular, Electrically Powered System foruse in Fracturing Underground Formations,” ('114 patent) which is hereinincorporated by reference in its entirety. Additionally, the surge tank122 may be mounted to blending modules that have been modified toincorporate other hydraulic fracturing equipment onto a singletransport. For example, surge tank 122 may be a mounted on a trailerconfigured to combine a blender unit with a hydration unit. In anotherexample, the surge tank 122 may be mounted on a trailer that combines ablender unit, a hydration unit, and a sand storage unit. Otherembodiments of the surge tank 122 could be a stand-alone unit that ismounted on its own transport or a stationary unit that is built on thewell site.

To reduce vibration and disturbances of other fracturing processes, thesurge tank 122 may include a vibration isolation system that includesprings, air bags, rubber-based dampeners (e.g., rubber bushings),and/or other vibration isolation components. The vibration isolationsystem may be configured to reduce the amount vibration experienced byother blender module components that could be mounted on the sametransport. For example, if the vibrator components mechanically causethe surge tank 122 to continuously or periodically vibrate and shake,the vibration isolation system absorbs and dampens the mechanicalvibration energy to avoid transfer of mechanical vibration energy thatcould potentially damage other blender module components, such as theblender tub and manifolds that are also mounted on the same transport.In embodiments where a vibration screen and/or sound waves are used todirectly liquefy sand without vibrating the surge tank 122, thevibration isolation system may dampen and reduce the amount of vibrationexperienced by the surge tank 122. Utilizing a vibration isolationsystem to dampen vibration from a vibration screen is discussed in moredetail in FIGS. 4A and 4B.

Although FIG. 1 illustrates that the fracturing sand storage site 102 donot directly deliver fracturing sand to the surge tank 122, otherembodiments of the wet fracturing sand agitation system can havefracturing sand storage sites 102 that include bulk storage tanks, suchas silos or bins that allow the fracturing sand to directly feed orconvey into the surge tank 122. The bulk storage tanks within thefracturing sand storage sites 102 may move the fracturing sand viagravity, conveyor belts, bucket elevators, augers, and/or othermechanical means known by persons of ordinary skill in the art to thesurge tank 122. Using FIG. 1 as an example, rather than have theconveyor system 106 directly supply wet fracturing sand into the surgetank 122, the conveyor system 106 can supply wet fracturing sand to afracturing sand storage site 102 that is elevated above the surge tank122. In another example, the wet fracturing sand agitation system maynot include a separate conveyor system 106, and instead replaces theseparate conveyor system 106 with a fracturing sand storage site 102elevated above the surge tank 122. In both examples, the fracturing sandstorage site 102 may use gravity to directly feed into the surge tank122.

FIG. 7 is a schematic diagram of an embodiment of a wet fracturing sandagitation system 700 that includes a bulk storage tank 702 positionedabove the surge tank 122. Recall that in FIG. 1, the bulk storage tank702 may be part of fracturing sand storage site 102. In one embodiment,the bulk storage tank 702 includes one or more vibrator components (notshown in FIG. 7) similar to the vibrating components as discussed abovefor the surge tank 122. Including the vibrator components with the bulkstorage tank 702 further assists in reducing the clumping of the wetfracturing sand and liquefying the wet fracturing sand. As shown in FIG.7, the bulk storage tank 702 directly feeds into the surge tank 122using gravity. A spout 704, such as a rubber boot, funnels the wetfracturing sand into the top opening of the surge tank 122. As the surgetank 122 liquefies the wet fracturing sand, a prime mover 706 (e.g., anelectric motor) drives the metering system 204 to meter the liquefiedwet fracturing sand into one or more blending modules.

FIG. 2 illustrates a top-down view of an embodiment of a surge tank 122that comprises a plurality of vibrating components 202. In FIG. 2, twosurge tanks 122 are mounted side-by-side to provide fracturing sand to adual configuration blender as described in more detail in the '114patent and U.S. Pat. No. 9,534,473, filed Dec. 16, 2015 by Jeffrey G.Morris et al. and entitled “Mobile Electric Power Generation forHydraulic Fracturing of Subsurface Geological Formations,” (the '473patent) which is also incorporated by reference in its entirety. Inother embodiments, a single surge tank 122 or more than two surge tanks122 may be used to provide fracturing sand to other types of blendermodules (e.g., a single surge tank 122 providing fracturing sand to aconventional diesel blender module).

For each of the surge tanks 122, vibrating components 202 may be mountedat one or more locations of the surge tank 122 to generate mechanicalvibration forces that agitate the surge tank 122. Using FIG. 2 as anexample, the vibrating components 202 are mounted on top or affixed toan outer top surface of the surge tank 122. In FIG. 2, the vibratingcomponents 202 are mounted or affixed above the opening where fracturingsand enters surge tank 122. The vibrating components 202 generatevibration forces aimed to break bonds between water and fracturing sandparticles. Other embodiments of the surge tanks 122 may includevibrating components 202 placed at other locations of the surge tank,such as the side walls and/or bottom of the surge tank 122. Each of thevibrating components 202 may be configured to generate mechanical forcesthat shake at least a portion of the surge tank 122 and/or the wet sandindependently at relatively high frequencies. For example, each of thevibrating components 202 may comprise one or more, electric motors (e.g.an electromagnetic motor), mechanical, pneumatic, and/or hydraulic meansthat move a set of weights to provide the mechanical vibration force toagitate the surge tank 122.

Each of the surge tanks 122 may comprise one or more metering systems204 that meter the wet fracturing sand into one or more blender modules(e.g., a blending tub). As shown in FIG. 2, the metering systems 204 arecoupled to the bottom of each of the surge tanks 122. In FIG. 2, themetering systems 204 are augers that are positioned at an incline tometer the liquefied wet fracturing sand to the blender modules. In otherembodiments of the surge tanks 122, the metering systems 204 may bepositioned in a straight or horizontal orientation. Correctlycontrolling and metering the liquefied wet fracturing sand into theblender modules affects the overall proppant concentration of thefracturing fluid (e.g., weight of the slurry). Controlling the overallproppant concentration is advantageous because the overall proppantconcentration could affect the proppant transport and the proppedfracture dimensions of the subsurface geological formations and therealization of the hydraulic fracturing treatment.

FIG. 3A illustrate a side view of an embodiment of a surge tank 122 thatcomprises vibrating components 202 and a vibration isolation system 304.The vibration isolation system 304 comprises a vibration isolator 306and a structure base 308. As shown in FIG. 3A, the vibration isolator306 is a vibration damping spring that prevents other fracturingequipment (e.g., drives, motors, and pumps) located on the sametransport from being affected by the vibration. Other embodiments of thevibration isolation system 304 may use and/or include other types ofvibration isolators 306, such as air bags, rubber-based dampeners andany combination thereof. The structure base 308 acts as a platform usedto support the surge tank 300 and the vibration isolators 306.

To regulate the moisture content of the wet fracturing sand, FIG. 3Aillustrates that the surge tanks 122 comprises a spray system configuredto provide water to maintain and/or adjust the moisture content of thewet fracturing sand. In one embodiment, the spray system includes aspray bar 310 at the top of the surge tank 122 and/or near the openingof where a conveyor transfers the fracturing sand to the surge tank 122.The spray bar 310 applies liquid, such as water, friction reducers,fracturing fluid, and/or other chemical and additives used to producefracturing fluid, to moisturize the wet fracturing sand held within thesurge tank 122. The spray bar 310 can also provide the benefit ofreducing the amount of silica dust released into the surrounding air andenvironment; thereby, reducing the risk of personal injury or death fromthe inhalation of silica dust. In another embodiment, in addition oralternative to using spray bars 310, the surge tank 122 includesperforated/jet spray piping (not shown in FIG. 3A) located within asurge tank 122 container that targets and moistures fracturing sandlocated in different areas of the surge tank 122. The perforated/jetspray piping may be capable of providing liquid content, such asspraying the liquid, within the surge tank 122. In addition, the spraybar 310 and/or perforated/jet spray piping may generate a pre-determineddepth of liquid within the surge tank 122 to liquefy the wet fracturingsand. The spray system may also be adapted to spray air to assist inliquefying the wet fracturing sand.

FIG. 3B illustrates a side view of another embodiment of a surge tank122 that comprises vibrating component 312 and water/air inlet 314. FIG.3B illustrates that the surge tank 122 includes a vibration component312, such as a pneumatic vibrator or piston vibrator, located near themetering system 204 (e.g., auger). The vibration component 312 isaffixed to the outer surfaces of the surge tank 122 and is located nearor proximate to the metering system 204. Affixing the vibrationcomponent 312 at the bottom of the surge tank 122 and proximate to themetering system 204 allows the vibration component 312 to providemechanical forces that agitate the bottom of the surge tank 122 prior tothe fracturing sand entering the metering system 204. Although FIG. 3Billustrates that the vibrating components 312 located at the bottomand/or proximate to the metering system 204 work in conjunction withvibrating components 202 affixed to the top of the surge tank 122, otherembodiments of the surge tank 122 may include the vibrating components312 near the metering system 204 without using the vibrating components202 located at the top of the surge tank 122. In FIG. 3B, the water/airinlet 314 is an inlet that supplies water and/or air to the spray bar310 as shown in FIG. 3A and/or the perforated/jet spray piping locatedwithin the surge tank 122

FIG. 4A illustrates a top-down view of an embodiment of a surge tank 122that comprises an internal vibrating component 402. FIG. 4A illustratesthat in addition to including vibrating components 202 located at thetop of the surge tank 122, one or more internal vibrating components 402may be located within the within the surge tank 122 that independentlyvibrate the fracturing sand without vibrating the surge tank 122. Theinternal vibrating component 402 may include a vibrating screen affixedwithin the surge tank 122 such that when wet fracturing sand passesthrough the vibrating screen, the mechanical vibration forces breakapart the bonds to liquefy the sand. The surge tank 122 may also includea vibration isolation system (e.g., rubber-based dampers) that isolateand prevent transferring of mechanical vibration forces generated fromthe internal vibrating component 402 to the surge tank 122. In anotherembodiment, rather than using an internal vibrating component 402positioned within the surge tank 122, one or more vibrating componentsmay each include a vibrating screen that is placed over the surface andat the entrance of the surge tank 122. This way, the vibrating componentwill assist in liquefying wet fracturing sand prior to entering thesurge tank 122.

In another embodiment, the internal vibrating components 402 may beconfigured to generate and project sound waves (e.g., frequency can varybeing subsonic, sonic or ultrasonic waves) into the wet fracturing sandcollected within the surge tanks 122. As the sound waves travel throughthe wet fracturing sand, the sound waves vibrate and break apart bondsbetween water and/or the fracturing sand particles. In one embodiment,the internal vibrating components 402 could be placed in a grid-like oran array arrangement where each of the vibrating components 402 targetone or more portions of the wet fracturing sand collected within thesurge tank 122. The frequency and amplitude generated by the internalvibrating components 402 to liquefy sand may depend on a variety offactors that include, but are not limited to the moisture content level,sand particle size, and/or sand particle density. For example, thefrequency of the internal vibrating components 402 may be cycled and/orimplemented in-phase or out-phase to generate the appropriate soundwaves.

FIG. 4B illustrates a side view of an embodiment of a surge tank 122that includes an internal vibrating component 402 and surge tankisolation components 404. As shown in FIG. 4B, the internal vibratingcomponent 402 is positioned between the opening of the surge tank 122and the metering system 204. The top of the surge tank 122 includessurge tank isolation components 404 that dampen vibration generated fromthe internal vibrating components 402. In FIG. 4B, the surge tankisolation components 404 may be used in conjunction with the vibrationisolation system 304 as described in FIG. 3B to dampen and isolatevibration forces.

FIG. 4B also illustrates that the surge tank 122 includes aperforated/jet spray piping 406 regulate the moisture content of the wetfracturing sand. The perforated/jet spray piping 406 is located withinthe surge tank 122 to target and provide moisture to different areas ofthe surge tank 122. Recall that the perforated/jet spray piping may becapable of providing liquid content, such as spraying the liquid, withinthe surge tank 122. In some instances, the spray bar 310 and/orperforated/jet spray piping 406 may generate a pre-determined depth ofliquid within the surge tank 122 to liquefy the wet fracturing sand.Both the spray bar 310 and perforated/jet spray piping 406 may also beadapted to spray air to assist in liquefying the wet fracturing sand.Although FIG. 4B illustrates that the surge tank 122 includes both thespray bar 310 and perforated/jet spray piping 406, other embodiments ofthe surge tank 122 can include the perforated/jet spray piping 406without the spray bar 310 or vice-versa.

FIGS. 5A and 5B are schematic diagrams of an embodiment of a mobileconveyor system 500 adapted to allow fracture sand transports to driveup to and directly load fracturing sand onto the mobile conveyor system500. FIG. 5A provides a top down view of the mobile conveyor system 500,and FIG. 5B provides a side view of the mobile conveyor system 500. Asshown in FIG. 5A, the mobile conveyor system 500 includes conveyorramps/walls 506 that can be positioned in different orientationsdepending on the operation modes. In transportation mode, the conveyorramps/walls 506 may be moved to and fastened at a substantially verticalposition. In a sand loading operation mode, the conveyor ramps/walls 506are laid down flat so that fracture sand transports are able to drive upto the mobile conveyor system 500 and load the fracturing sand onto themobile conveyor system's 500 platform. In a sand transferring operationmode, the conveyor ramps/walls 506 may be configured at an angledposition (e.g., at an angle less than the vertical position) and vibrateto move sand onto to the mobile conveyor system's 500 platform.

During sand transferring operation mode, the mobile conveyor system's500 platform includes a hopper 504 that funnels the fracturing sand tothe conveyor transport component 502 (e.g., a conveyor belt, augers,etc.). The conveyor transport component 502 then moves the fracturingsand to a conveyor assembly 508, which then transports the fracturingsand to a surge tank. In FIGS. 5A and 5B, one or more portions of theconveyor assembly 508 may be adapted to disconnect and move to aside-by-side position in transportation mode, and then subsequentlyconnect and move to an extended position in operation mode. FIG. 5B alsoillustrates that the trailer connection component 510 may be detachableand/or configured to dropped to a lower vertical position so thatfracturing sand transports are able to drive up and load the fracturingsand onto the mobile conveyor system's 500 platform during sandtransferring operation mode.

FIG. 6 is a flow chart of an embodiment of a method 600 to provide andutilize wet fracturing sand for hydraulic fracturing. Method 600 maystart at block 602 by delivering wet fracturing sand received from aprocessing plant to a well site. In one embodiment, method 600 maydeliver the wet fracturing sand without using specialized transport(e.g., dry bulk tank trailers) or transportation containers designed toprevent exposure of rain, moisture, and/or other environmental factorsthat could impact the dryness level of the fracturing sand. For example,method 600 may use uncovered containers and conventional dump truckswith an open-box bed. Method 600 may then move to block 604 and storethe wet fracturing sand at and/or near the well site. At block 604,method 600 may store the fracturing sand without using specializedstorage facilities and/or containers (e.g., storage silos) that maintaindryness of the fracturing sand. To prevent the generation of silicadust, which the inhalation may lead to chronic personal injury and/orcause disability or death, method 600 may use a liquid spray system tomaintain a pre-determined moisture level range for the wet fracturingsand.

Method 600 continues to block 606 and delivers the wet fracturing sandfrom the storage site to one or more surge tanks. In one embodiment,method 600 may transport the wet fracturing sand using mechanical means(e.g. front end loaders and/or conveyor systems). The conveyor systemmay be used to provide a steady and consistent flow of the wetfracturing sand into the surge tanks. Afterwards, method 600 moves toblock 608 and liquefies the wet fracturing sand within the surge tanks.In one embodiment, method 600 liquefies the wet fracturing sand by usinga plurality of vibration components that reduce clumping of the wetfracturing sand by breaking bonds (e.g., cohesion bonds) between waterand the fracturing sand particles. In another embodiment, the method 600liquefies the wet fracturing sand by generating and projecting soundwaves (e.g., frequency can vary being subsonic, sonic or ultrasonicwaves) into the wet fracturing sand collected within the surge tanks tobreak apart bonds between water and/or the fracturing sand particles.Method 600 then moves to block 610 and meters the liquefied sand to ablender module for mixing proppants with fluid to generate fracturingfluid. Method 600 may meter and control the amount of liquefied sandusing a metering system (e.g., one or more augers).

At least one embodiment is disclosed and variations, combinations,and/or modifications of the embodiment(s) and/or features of theembodiment(s) made by a person having ordinary skill in the art arewithin the scope of the disclosure. Alternative embodiments that resultfrom combining, integrating, and/or omitting features of theembodiment(s) are also within the scope of the disclosure. Wherenumerical ranges or limitations are expressly stated, such expressranges or limitations may be understood to include iterative ranges orlimitations of like magnitude falling within the expressly stated rangesor limitations (e.g., from about 1 to about 10 includes, 2, 3, 4, etc.;greater than 0.10 includes 0.11, 0.12, 0.13, etc.). The use of the term“about” means±10% of the subsequent number, unless otherwise stated.

Use of the term “optionally” with respect to any element of a claimmeans that the element is required, or alternatively, the element is notrequired, both alternatives being within the scope of the claim. Use ofbroader terms such as comprises, includes, and having may be understoodto provide support for narrower terms such as consisting of, consistingessentially of, and comprised substantially of. Accordingly, the scopeof protection is not limited by the description set out above but isdefined by the claims that follow, that scope including all equivalentsof the subject matter of the claims. Each and every claim isincorporated as further disclosure into the specification and the claimsare embodiment(s) of the present disclosure.

While several embodiments have been provided in the present disclosure,it should be understood that the disclosed systems and methods might beembodied in many other specific forms without departing from the spiritor scope of the present disclosure. The present examples are to beconsidered as illustrative and not restrictive, and the intention is notto be limited to the details given herein. For example, the variouselements or components may be combined or integrated in another systemor certain features may be omitted, or not implemented.

In addition, techniques, systems, subsystems, and methods described andillustrated in the various embodiments as discrete or separate may becombined or integrated with other systems, modules, techniques, ormethods without departing from the scope of the present disclosure.Other items shown or discussed as coupled or directly coupled orcommunicating with each other may be indirectly coupled or communicatingthrough some interface, device, or intermediate component whetherelectrically, mechanically, or otherwise.

What is claimed is:
 1. A method for creating fracturing fluid, themethod comprising: receiving wet fracturing sand at a surge tank mountedon a transport; liquefying the wet fracturing sand within the surge tankusing at least one vibration component attached to the surge tank,producing a liquefied wet fracturing sand; receiving, at an augermounted on the transport, the liquefied wet fracturing sand from thesurge tank; and metering the liquefied wet fracturing sand to a blendingtub that produces a fracturing fluid, wherein the amount of theliquefied wet fracturing sand outputted to the blending tub affects anoverall proppant concentration within the fracturing fluid.
 2. Themethod of claim 1, wherein liquefying the wet fracturing sand locatedwithin the surge tanks comprises mechanically vibrating the surge tankusing the at least one vibrating component attached to the surge tank.3. The method of claim 2, further comprising dampening vibration forcesgenerated from mechanically vibrating the surge tank.
 4. The method ofclaim 1, wherein liquefying the wet fracturing sand within the surgetank comprises: generating sound waves using the at least one vibrationcomponent; and directing the sound waves towards the wet fracturing sandwithin the surge tank.
 5. The method of claim 1, further comprisingoutputting liquid onto the wet fracturing sand after receiving the wetfracturing sand at the surge tank.
 6. The method of claim 5, whereinoutputting liquid onto the wet fracturing sand comprises spraying liquidusing a spray bar affixed to the surge tank.
 7. The method of claim 5,wherein outputting liquid into the wet fracturing sand comprisesoutputting a liquid to maintain a predetermined amount of the liquidwithin the surge tank.
 8. The method of claim 1, wherein liquefying thewet fracturing sand within the surge tank comprises mechanicallyvibrating the wet fracturing sand using a vibration screen prior to thewet fracturing sand entering the surge tank.
 9. The method of claim 1,further comprising mixing the liquefied wet fracturing sand with a fluidto generate the fracturing fluid, wherein the blending tub is mounted onthe transport.
 10. The method of claim 1, further comprisingsynchronizing the surge tank with a sand delivery system to receive thewet fracturing sand at a target rate that is associated with a pump ratefor pumping the fracturing fluid into a wellbore.
 11. The method ofclaim 1, wherein the surge tank is configured to receive wet fracturingsand at a rate greater than 20,000 pounds of sand per minute.
 12. Asystem for creating fracturing fluid, comprising: a surge tank mountedon a transport and configured to receive wet fracturing sand; avibration component disposed with the surge tank and configured tovibrate the wet fracturing sand received by the surge tank to generateliquefied wet fracturing sand; and a metering system coupled to thesurge tank and mounted on the transport, wherein the metering system isconfigured to: receive the liquefied wet fracturing sand from the surgetank; and control an amount of the liquefied wet fracturing sandoutputted to a blending tub that produces a fracturing fluid, whereinthe amount of the liquefied wet fracturing sand outputted to theblending tub affects an overall proppant concentration within thefracturing fluid.
 13. The system of claim 12, further comprising asecond vibration component disposed with the surge tank.
 14. The systemof claim 13, wherein the vibration component is mounted at a base of thesurge tank and generates mechanical vibration at the base of the surgetank, and wherein the second vibration component is a vibration screenposition at an opening of the surge tank where the wet fracturing sandenters the surge tank.
 15. The system of claim 12, wherein the surgetank is configured to synchronize with a sand delivery system to receivethe wet fracturing sand at a predetermined rate associated with a pumprate for pumping fracturing fluid into a wellbore.
 16. The system ofclaim 12, wherein the vibration component is positioned within the surgetank and is configured to: generate sound waves; and direct the soundwaves to traverse through the wet fracturing sand.
 17. The system ofclaim 16, further comprising a spray bar affixed to the surge tank,wherein the spray bar is configured to output a liquid onto the wetfracturing sand.
 18. A method for creating fracturing fluid, the methodcomprising: receiving fracturing sand at a surge tank mounted on atransport, wherein the surge tank is synchronized with a sand deliverysystem to receive the fracturing sand at a predetermined rate associatedwith a pump rate for pumping a fracturing fluid into a wellbore;vibrating the fracturing sand as the fracturing sand enters the surgetank; receiving, at an auger and after vibrating the fracturing sand,the fracturing sand from the surge tank; and metering the fracturingsand to a blending tub that produces the fracturing fluid, wherein theamount of the fracturing sand outputted to the blending tub affects anoverall proppant concentration within the fracturing fluid.
 19. Themethod of claim 18, further comprising outputting liquid onto the wetfracturing sand after receiving the wet fracturing sand at the surgetank.
 20. The method of claim 18, further comprising a vibrating screenaffixed within the surge tank.